Superabrasive compact, drill bit using same, and methods of fabricating same

Abstract

Superabrasive compacts, methods of fabricating such compacts, and drilling tools that may utilize such compacts are disclosed. In one aspect of the present invention, a superabrasive compact includes a substrate and a superabrasive table attached to the substrate. At least one constituent of the superabrasive table exhibits a substantially monotonic distribution of size, concentration, or both in a selected direction of the superabrasive table. In another aspect of the present invention, a method of fabricating a superabrasive article is disclosed. A plurality of particles may be provided that exhibit a substantially monotonic distribution of particle size, concentration, or both in a selected direction. The particles may be subjected to a high-temperature, high-pressure process to consolidate and form a self-supporting body.

1. A polycrystalline diamond compact, comprising:
 a substrate; and 
 a polycrystalline diamond table attached to the substrate, the polycrystalline diamond table including an interfacial surface bonded to the substrate and an opposing cutting surface, the polycrystalline diamond table including diamond grains exhibiting a substantially constant average grain size in a thickness direction, the polycrystalline diamond table further including a metal-containing constituent exhibiting a substantially monotonic concentration distribution that decreases toward the cutting surface, substantially each value of the substantially monotonic concentration distribution being less than a previous value. 
 
     
     
       2. The polycrystalline diamond compact of  claim 1  wherein the metal-containing constituent comprises at least one of metal carbide particles or cemented metal carbide particles. 
     
     
       3. The polycrystalline diamond compact of  claim 1  wherein the substrate comprises a cemented carbide substrate. 
     
     
       4. The polycrystalline diamond compact of  claim 1  wherein the substantially monotonic concentration distribution is a stepped distribution. 
     
     
       5. The polycrystalline diamond compact of  claim 1  wherein the substantially monotonic concentration distribution is substantially linear. 
     
     
       6. The polycrystalline diamond compact of  claim 1  wherein the metal-containing constituent comprises metal carbide particles. 
     
     
       7. The polycrystalline diamond compact of  claim 1  wherein the metal-containing constituent comprises cemented metal carbide particles. 
     
     
       8. The polycrystalline diamond compact of  claim 1  wherein the polycrystalline diamond table comprises a region at least proximate to the cutting surface that is substantially free of the metal-containing constituent. 
     
     
       9. A rotary drill bit including a bit body adapted to engage a subterranean formation during drilling and at least one polycrystalline diamond cutting element affixed to the bit body, wherein the at least one polycrystalline diamond cutting element comprises the polycrystalline diamond compact according to  claim 1 . 
     
     
       10. A polycrystalline diamond compact, comprising:
 a substrate; and 
 a polycrystalline diamond table attached to the substrate, the polycrystalline diamond table including an interfacial surface bonded to the substrate and an opposing cutting surface, the polycrystalline diamond table including diamond grains exhibiting a substantially monotonic grain size distribution that decreases toward the cutting surface, substantially each value of the substantially monotonic grain size distribution being less than a previous value, the polycrystalline diamond table further including a metal-containing constituent exhibiting a substantially monotonic concentration distribution that decreases toward the cutting surface, substantially each value of the substantially monotonic concentration distribution being less than a previous value. 
 
     
     
       11. The polycrystalline diamond of  claim 10  wherein the substrate comprises a cemented carbide substrate. 
     
     
       12. The polycrystalline diamond of  claim 10  wherein the substantially monotonic concentration distribution of the diamond grains and/or the metal-containing constituent is stepped distribution. 
     
     
       13. The polycrystalline diamond of  claim 10  wherein the substantially monotonic concentration distribution of the diamond grains and/or the metal-containing constituent is substantially linear. 
     
     
       14. The polycrystalline diamond compact of  claim 10  wherein the metal-containing constituent comprises metal carbide particles. 
     
     
       15. The polycrystalline diamond compact of  claim 10  wherein the metal-containing constituent comprises cemented metal carbide particles. 
     
     
       16. The polycrystalline diamond compact of  claim 10  wherein the metal-containing constituent comprises metal carbide particles, cemented metal carbide particles, or combinations thereof. 
     
     
       17. The polycrystalline diamond compact of  claim 10  wherein the polycrystalline diamond table comprises a region at least proximate to the cutting surface that is substantially free of the metal-containing constituent. 
     
     
       18. A rotary drill bit including a bit body adapted to engage a subterranean formation during drilling and at least one polycrystalline diamond cutting element affixed to the bit body, wherein the at least one polycrystalline diamond cutting element comprises the polycrystalline diamond compact according to  claim 10 .